I think it was the suck test that set the code, since the code set is for random misfire. It was pending first. But yea, that will clear upon reset/hard disconnect. The EGR isn't active while stationary, only at cruising speeds. The also produces 400 series codes, not misfire. It can ONLY produce a misfire when opened. You forced it open with the suck test causing the engine to gag on exhaust gases....explains it, if your following this crap lol. Yea, resetting the KAM (KeepAliveMemory) will remedy.

 

Lol I follow ya! I did the disconnect and no improvement. I then proceeded to redo the intake and make sure everything was as it should be. Same result.

Then, just as I was about to throw in the towel and call it a career, I heard what sounded like a blown plug. Sure enough, number 7 was loose in the hole and the plug was destroyed! Cause of issue identified! The bad part is that the Lisle threaded insert came out with it (I know this is not the preferred repair method, but it worked years ago for a guy supporting a family of seven and putting kids through college). So, I have reinstalled the plug and insert and am in the process of letting the thread locker set. I will let it set overnight and see what I got tomorrow after work.

Hopefully it will hold a little while longer. The next step after this is likely new heads, which I know will put a dent in the budget.

 

Nah, it's still an easy fix, 20 minutes one you get to the problem. Big sert it, good as new.

 

Thanks for the encouragement! I was gonna drown my sorrows in some George Jones and a 12 pack, but I can see there is hope! Lol

In all seriousness, your wisdom and advice is what makes this forum so valuable! You are truly the 10th Gen Guru! Thanks man!

 

No problem, for the most part, you fixed/clean things that needed doing, why stop there ? It's definitely not done for , not so much as hard to fix...thanks to the BIG SERT kit anyway. Look into it, 100 times easier than head removal. There use to be folks out there that will rent their Time Sert kit. You just supply the Serts. Makes for a cheap fix.

 

Yes, I am definitely looking into the Big Sert kit.

The good news, for now anyway, is that the Lisle thread insert seems to be holding. I looked at the old plug that came out and it looks as though it just worked it's way loose rather that stripping the threads. The new thread insert is holding and I will definitely be keeping a close eye on it until I can afford the Big Sert kit.

 

Well that's much better than "destroyed" lol. If you can get at least 28' lbs on it, then it should stay in place. It's between 3/4 to 1 full turn after seat. That's the spec for these heads now..inserts and plugs. Otherwise they will work back out unfortunately.

 

Yeah I was able to get 28 lbs on it. Drove it about 20 miles today and it is holding great so far. I am going to recheck it this weekend.

I am kicking myself for never suspecting the ignition system for being the cause of my stalling issues. I had been chasing the issue down for a month now and it turned out to be extremely simple. The crazy thing is that it never threw any cylinder specific misfire codes. At least I know now for future reference.

 

That's because the coil was firing. The cylinder itself isn't monitored. The misfire monitor also has to reach a certain misfire count within a single drive cycle, then starts all over again once you key off. The only way you can monitor misfires is through live data with your cell or smart phone using the Torque/Torque Pro app. It's a cheap app you can download for your phone off the internet, it's blue tooth as well. Handy little app that use to cost just $4.75 lol. It shows every misfire and which cylinder.
The other way is through Mode $$06 which shows cylinder misfire history. Some Cell phones support that as well. Yea , they made it easy finally for the DIY'er. Basic scanners don't show none of this yet, I guess it's still fairly new, 5 years or so since it's inception. Techs use it as well at Ford. I seen one using while I there, diagnosing a V10 misfire lol. Great app! There's other PIDS and ones you can add on to software.

Never the less, that shouldn't have caused a stalling issue. So that's a little mysterious. Regardless, it's fixed, that's all that counts.